Double Stroke Vial Filling Machine

Description

Double Stroke Vial Filling Machine is a specialized semi-automatic or automatic device primarily used in the pharmaceutical industry for precise liquid filling into glass vials, such as those for injectables, vaccines, or biopharmaceuticals. The “double stroke” refers to the filling mechanism where the piston or syringe pump performs two strokes per cycle: an upward stroke to draw in the liquid from the reservoir and a downward stroke to dispense it into the vial. This design allows for adjustable fill volumes by varying the stroke length, enabling accurate dosing without frequent recalibration. Vial Filling Machine are typically compact, compliant with cGMP standards, and designed for sterile environments, often integrated with laminar airflow systems to minimize contamination risks.

Vial Feeding: Vials are manually or automatically fed via an in-feed turntable or unscrambler.

Positioning: The star wheel grips the vial and rotates it to the filling station.

Filling Cycle: The piston draws liquid on the upstroke and dispenses it on the downstroke. Volume is adjusted by altering the eccentric cam’s stroke length—no tools required for minor changes.

Post-Filling: Vials move to stoppering (vacuum placement of rubber bungs) and optional capping/sealing stations.

Ejection: Filled and sealed vials exit via an out-feed turntable for further processing like labeling or inspection.

If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Double Stroke Vial Filling Machine

Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
Variable A.C. frequency drive for speed adjustment.
Suitable for the filling Volume of 2ml to 250ml.

Digital Vial Counter for counting production output.
“No Vial – Machine Stop” System.
On-line Mechanism., “No Vial – No Filling” System.
Easy to validate filling system for small/large batch production.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Double Stroke Vial Filling Machine

The incoming dry vials (sterilized and siliconized) are fed through the unscrambler and suitably guided on the moving Delrin slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists of Filling Head, Syringes & Nozzles; Syringes & Nozzles are made of AISI SS 316L materials. A Star Wheel is provided which holds the vial during filling operation. A sensor is provided for ”No Vial-No Filling” operation. Syringes are mounted on eccentric block and driving through bottom main gear box. Volume can be increase & decrease by increasing or decreasing stroke length of piston as per filling size. Syringes is having non return valve for sucking and delivering situation to avoid volume variation. Liquid reaches to filling nozzles through silicon transparent pipe. Nozzles having up & down movement with help of cam mechanism, and it come down when vial hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers two vials together on conveyor for rubber stoppering operation.

Stoppering unit consist of Star wheel, Vibrator unit and Bowl. The sterilized and siliconized rubber stoppers stored in the vibrator bowl moves vertically to the rubber stopper chute. The vial is hold firmly by starwheel, which will be in continuous rotary motion and vial which is coming from filling unit get in to starwheel and move in rotary direction along with starwheel, during movement it picks up the rubber stopper from the exit end of the chute and rubber stopper pressed by fix single pressing roller, which is spring loaded. Then vial further move on conveyor and collected on out feed starwheel for next sealing operation.

Technical Specification of Double Stroke Vial Filling Machine

Model	ALVF-40	ALVF-80	ALVF-120	ALVF – 250
Filling Heads	Two	Four	Eight	Twelve
Production Rate	Up to 40 Vials/Minute	Up to 80 Vials/Minute	Up to 150 Vials/Minute	Up to 250 Vials/Minute
Vial Diameter	15mm to 70mm	15mm to 70mm	15mm to 70mm	15mm to 70mm
Vial Height	25mm to 140mm	25mm to 140mm	25mm to 140mm	25mm to 140mm
Filling Precision	±1%	±1%	±1%	±1%
Power Required	1 H.P.	1.5 H.P.	2 H.P.	2 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2050mm (L) x 850mm (W) x 1700mm (H)	2200mm (L) x 850mm (W) x 1700mm (H)	3000mm (L) x 945mm (W) x 1700mm (H)	3500mm (L) x 945mm (W) x 1700mm (H)

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

Types of Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Filling Machine

Advantages of Double Stroke Vial Filling Machine

Precision and Flexibility: Stroke adjustment allows filling from 0.5 ml to 20 ml without part changes.

Efficiency: Reduces manual labor and errors; compact footprint for cleanrooms.

Compliance: Meets FDA/USP standards for sterility, with features like particle-free external cleaning integration.

Key Components of Double Stroke Vial Filling Machine

Filling Mechanism: Utilizes stainless steel (SS 316L) syringes or pistons mounted on an eccentric block, driven by a gearbox. The double stroke ensures smooth, drip-free filling with accuracy of ±0.5% to 1%, depending on the liquid viscosity and vial size.

Vial Handling: Equipped with a star wheel or rotary indexing system to hold and position vials (typically 2 ml to 30 ml) during filling. Includes a “No Vial-No Fill” sensor to prevent overfilling or waste.

Speed and Capacity: Outputs range from 20 to 100 vials per minute (VPM) for semi-automatic models, scalable to higher speeds in automated setups. Suitable for small to medium batch production.

Additional Integrations: Often combined with rubber stoppering (bunging) and capping units in a monoblock design, reducing exposure time and contamination. Features like peristaltic pumps for corrosive liquids or vacuum-assisted stoppering enhance versatility.

Sterility and Safety: Operates under laminar flow protection; minimal distance between filling and stoppering stations. Easy-to-clean design with no dead ends, and options for isolator or RABS compatibility.

FAQ for Double Stroke Vial Filling Machine

What is a Double Stroke Vial Filling Machine?

A Double Stroke Vial Filling Machine is a precision-engineered pharmaceutical equipment used for accurate aseptic filling of sterile liquids (such as injectables, vaccines, antibiotics, and biologics) into glass vials. The “double stroke” refers to the piston/syringe pump mechanism that performs two strokes per cycle—one to draw liquid from the reservoir and one to dispense it into the vial. This design enables highly adjustable fill volumes with excellent accuracy (typically ±0.5% to ±1%) and supports efficient production in sterile environments under laminar airflow. It is available in models ranging from 2 filling heads (up to 40 vials/min) to 12 heads (up to 250 vials/min).

What is the filling capacity and range of the Double Stroke Vial Filling Machine?

The machine handles a wide filling volume range of 2ml to 250ml, with flexibility to adjust from as low as 0.5ml to 20ml in many setups without changing parts (via stroke length adjustment).
Production output varies by model:
– ALVF-40 (2 heads): Up to 40 vials/minute
– ALVF-80 (4 heads): Up to 80 vials/minute
– ALVF-120 (8 heads): Up to 150 vials/minute
– ALVF-250 (12 heads): Up to 250 vials/minute

It accommodates vials with diameters of 15mm to 70mm and heights of 25mm to 140mm, making it suitable for small to medium batch production.

What are the key features and benefits of the Double Stroke Vial Filling Machine?

Key features include:
– All product contact parts made of Stainless Steel 316L (non-contact: 304)
– “No Vial – No Filling” and “No Vial – Machine Stop” systems
– Digital vial counter
– Variable AC frequency drive for speed control
– Bottom-up filling with diving nozzles to reduce foaming
– cGMP compliance with optional PLC/HMI and IQ/OQ documentation

Benefits include high filling accuracy with minimal wastage, reduced cross-contamination risk, easy validation, low maintenance, and nearly double the output efficiency compared to single-stroke systems for medium batches. It is ideal for both low- and high-viscosity liquids.

How does the Double Stroke mechanism work in the Vial Filling Machine?

The machine uses an eccentric block and gearbox-driven syringes (made of SS 316L). Vials move via a Delrin slat conveyor and star wheel. The piston performs a double stroke: an upward stroke draws liquid through a non-return valve, and a downward stroke dispenses it precisely into the vial via nozzles that dive and retract via cam mechanism. Volume is easily adjusted by changing the stroke length. A sensor ensures no filling occurs without a vial present, and filled vials proceed to rubber stoppering. This setup ensures consistent dosing and sterility.

Is the Double Stroke Vial Filling Machine suitable for sterile pharmaceutical production?

Yes, it is specifically designed for sterile environments and complies with cGMP, FDA, and USP standards. Features like aseptic piston/peristaltic pumps, no cross-contamination design, and compatibility with laminar airflow systems minimize contamination risks. It is widely used in the pharmaceutical, biotech, and cosmetic industries for filling vaccines, suspensions, and other injectable liquids. Optional nitrogen flushing and easy-to-clean design further support validation for small or large batch sterile production.

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